Flexible heat sealable decorative articles and method for making the same

ABSTRACT

Various flexible heat sealable decorative articles and methods of making the same are described. The flexible heat sealable decorative articles are lightweight and can be combined with other decorative elements, such as metalized films. Various decorative are mixed or combined with one another to form highly attractive flexible heat sealable decorative articles.

CROSS REFERENCE TO RELATED APPLICATION

-   The present application is a continuation application of U.S.    application Ser. No. 14/035,399 with a filing date of Oct. 14, 2013    entitled “FLEXIBLE HEAT SEALABLE DECORATIVE ARTICLES AND METHOD FOR    MAKING THE SAME;” which claims the benefit of and priority to U.S.    Provisional Application Ser. Nos. 61/813,945 with a filing date of    Apr. 19, 2013, 61/760,490 with a filing date Feb. 4, 2013,    61/758,607 with a filing date of Jan. 30, 2013, 61/754,410 with a    filing date of Jan. 18, 2013, 61/718,329 with a filing date of Oct.    25, 2012, 61/714,586 with a filing date of Oct. 16, 2012 and    61/713,210 with a filing date of Oct. 12, 2012 all entitled    “Decorative Metalized Films”, each of which is incorporated herein    by this reference in its entirety.

FIELD

This disclosure generally relates to flexible heat sealable decorativearticles, the flexible heat sealable decorative articles are lightweightand can be combined with other decorative elements, such as metalizedfilms.

BACKGROUND

For many years people have created decorative articles composed ofcontrasting materials, special effects, prints, and the like. Thesedecorative articles have included flock, woven or knit textiles, andmetalized films. While these articles have, in many cases, beenattractive to viewers, they have generally lacked one or more of desireddesign features of richness of color, luminosity, flexibility, andlightness of weight, which has caused the articles to have low perceivedvalue. In fact, decorative articles have not kept pace with significantadvances in textile design and construction and the explosion of specialvisual effects and higher graphic art standards and requirementsrealizable in the digital age, which have collectively resulted inhigher expectations associated with indicia of perceived value.

There is therefore a need for a new class of decorative articles meetingthe more stringent aesthetics and functional requirements of today'ssociety.

SUMMARY

These and other needs are addressed by the various embodiments andconfigurations of the present disclosure. This disclosure relatesgenerally to flexible heat sealable decorative articles. Morespecifically, this disclosure relates to lightweight, flexible heatsealable decorative articles and to methods for making the same.Furthermore, these lightweight, flexible heat sealable decorativearticles can be combined with other decorative elements, such asmetalized films.

The lightweight, flexible heat sealable decorative articles can beadhered to any item of commerce. For example, decorative articles can bepermanently adhered to items of apparel. Non-limiting examples ofdecorative articles include nametags, company logos, team logos, badges,emblems, trade or brand names, appliqués, heat transfers, patches,stickers, and a variety of artistic and graphic design elements. Thedecorative articles can be formed to have the look and appearance ofmetals, without the weight and expense of metals. For example, thedecorative articles can have the appearance of gold, silver or otherprecious metals. Moreover, the decorative articles can include multipledecorative elements such as flock, woven textiles, knit textiles, andpolymeric coatings and films. These other decorative elements can beconfigured with the flexible heat sealable decorative article to providecontrasting decorative properties (e.g., surface geometries andtextures), light or optical reflectivities (e.g., brightness and/or highor low luster and which is typically a function of yarn opticalproperties and textile construction), constructions, colors, and/ordesigns), which can provide not only a visual interplay between thecontrasting materials (which, as noted, are decorative elements of awhole or single design or image) but also a greater richness and depthof the design or image (e.g., an appearance of 3-D dimensionality).Stated another way, the use of multiple decorative elements (differenttypes of decorative elements and/or common types of decorative elementshaving differing decorative properties) can greatly increase theperceived value of a design by creating the depth, contrast, andinterplay of the various decorative elements. It can permit or enable adesign to be subdivided into logical design or decorative elements,which are emphasized (e.g., emphasis effected by locating decorativeelement on top or foreground) or subordinated (e.g., subordinationeffected by locating decorative element on the bottom or background),thereby adding to the article a real or perceived 3-D dimensionality andmaking logical “design sense” to a viewer.

The formation of the flexible, heat sealable decorative articles bylaser etching and/or engraving allows for a high level of customizationof the decorative articles by combining digital graphics technology. Theuse of digital graphics technology substantially eliminates tooling,screens, decrease set-up time. Moreover, the use of digital graphicstechnology enables custom individual images to be prepared and/ormodifying images during manufacturing. Digital graphics can includedimensional graphic design features. Such dimensional graphic featuresinclude digital printing of ink directly onto decorative article to forma three-dimensional appearing image, or to form a image that appears toembossed. Such images have a higher perceived value.

Heat sealable decorative articles have a higher perceived value byconsumers due to the ability to survive multiple wash cycles.Furthermore, heat sealable articles are valued for their convenience ofapplicability to substrates.

The decorative articles according to this disclosure combine decorativeelements in previously unknown configurations and with previouslyunattainable flexibility and lightness. Synergistic visual and/ordimensional affects are provided by a complimentary combination ofmaterials and design elements, with the added advantages of beingflexible and lightweight.

Some embodiments of this disclosure include a decorative article thatcan comprise an adhesive layer and a flexible polymeric layer. Theadhesive layer can be adhered to the flexible polymeric layer.Typically, the flexible polymeric layer can have one or more voids. Theflexible polymeric layer is generally positioned on viewable decorativesurface to be visible to a viewer of the decorative article. Thedecorative surface can be the viewable surfaces of any item of commerce.Non-limiting examples of such viewable decorative surfaces is typicallyintended to be viewed by a view when the decorative article is beingused for its intended purpose, e.g. when the decorative article isadhered to attached to an item of commerce. The surfaces of an item ofapparel such the exterior and neck portions of shirts and blouses, theexterior and waist band portions of pants and slacks, and so forth.

The decorative article typically has a density of no more than about 1.5g/cm³. The decorative article typically has a tensile strength of nomore than about 10⁷ Pascals. The tensile strength generally refers to ameasure of the ability to withstand pulling stress, and is typicallydefined as the stress (stretching force per unit area) required to breakthe article. The decorative article commonly has a modulus of elasticityor flex strength of no more than about 10⁹ Pascals. The modulus ofelasticity, flex (as known as flexural) strength, or cross-breakingstrength generally refers to a measure of the bending strength orstiffness expressed as the stress required to break the article byexerting a torque on it.

Moreover, some embodiments can include a decorative article that cancomprise a flexible polymeric layer and an adhesive layer. The flexiblelayer can have one or more voids. Generally, an insert is positioned inthe one or more voids. The decorative article typically includes theinsert positioned in some but not all of the one or more voids.Moreover, the adhesive layer can be visible in the other of one or morevoids not having the insert positioned therein.

The decorative article can have an optically transmissive layerpositioned between the flexible polymeric layer and the adhesive layer.Typically, the optically transmissive layer comprises a thermoplasticresin film. In some configurations, a color-enhancing layer ispositioned between the optically transmissive layer and the adhesivelayer. Generally, the color-enhancing layer comprises a translucentcolor-containing ink layer.

The flexible polymeric layer can comprise a metalized film having ametallic appearance. The flexible polymeric layer can comprise one ofpolyester or polyurethane. Generally, the flexible polymeric layercomprises polyester. More generally, the flexible polymeric layercomprises polyurethane. Furthermore, the flexible polymeric layer cancomprise a sublimation printable polymeric material. Commonly, theflexible polymeric layer can contain a sublimation dye-printed image.The flexible polymeric layer can have a density of no more than about1.5 g/cm³. Generally, flexible polymeric layer has a tensile strength ofno more than about 10⁷ Pascals. The flexible polymeric layer can have amodulus of elasticity or flex strength of no more than about 10⁹Pascals.

The adhesive layer can have a color. The adhesive layer can comprise oneof polyester or polyurethane. Generally, the adhesive layer comprisespolyester. More generally, the adhesive layer comprises polyurethane.

The decorative article can further comprise the flexible polymeric layeradhered to an item of apparel by the adhesive layer.

Some embodiments of this disclosure include a method having the steps ofproviding an decorative article intermediate, registering the decorativearticle intermediate with a laser etching system, and etching thedecorative article intermediate by contacting the decorative articleintermediate with a laser beam generated by the laser system. Thecontacting of the laser beam with the decorative article intermediategenerally forms one or more voids in decorative article intermediate.

Commonly the decorative article intermediate can comprise an adhesivelayer adhered to a flexible polymeric layer. The one or more voids aretypically formed in the flexible polymeric layer by the contacting ofthe laser beam with the decorative article intermediate. The adhesivelayer can be visible within the one or more voids.

The decorative article intermediate can comprise a flexible polymericlayer. The one or more voids are generally formed in the flexiblepolymeric layer by the laser beam contacting the flexible polymericlayer. Furthermore, after forming one or more voids in the flexiblepolymeric layer, an adhesive layer can be contacted with the flexiblepolymeric layer. Generally, after contacting the adhesive layer with theflexible polymeric layer, the adhesive layer can be visible within theone or more voids.

The step of registering can comprise one of a mechanical registration,optical registration, electro-mechanical registration, computerizedregistration, or combination thereof. Typically, the step of registeringcomprises one of optical registration, electro-mechanical registration,computerized registration, or combination thereof. More typically, thestep of registering is an optical registration. Even more typically, thestep of registering is an electro-mechanical registration. Yet even moretypically, the step of registering is a computerized registration.

The step of contacting of the laser bean with the decorative articleintermediate can comprise a sequential contacting of the laser beam withthe decorative intermediate. Generally, the contacting of a laser beamwith the decorative article intermediate removes at least some of thedecorative article intermediate. More generally, each sequentialcontacting of the laser beam with the decorative article removes atleast some of the decorative article intermediate contained in the oneor more voids. Moreover, when the decorative intermediate comprises aflexible polymeric layer adhered to an adhesive layer, the laser etchingtypically comprises sufficient laser beam energy and sufficientsequential passes of the laser beam to remove at least most, if not all,of the decorative article intermediate contained in the one or morevoids but little, if any, of the second layer material.

These and other advantages will be apparent from the disclosure of theaspects, embodiments, and configurations contained herein.

As used herein, “at least one”, “one or more”, and “and/or” areopen-ended expressions that are both conjunctive and disjunctive inoperation. For example, each of the expressions “at least one of A, Band C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “oneor more of A, B, or C” and “A, B, and/or C” means A alone, B alone, Calone, A and B together, A and C together, B and C together, or A, B andC together. When each one of A, B, and C in the above expressions refersto an element, such as X, Y, and Z, or class of elements, such asX₁-X_(n), Y₁-Y_(m), and Z₁-Z_(o), the phrase is intended to refer to asingle element selected from X, Y, and Z, a combination of elementsselected from the same class (e.g., X₁ and X₂) as well as a combinationof elements selected from two or more classes (e.g., Y₁ and Z_(o)).

It is to be noted that the term “a” or “an” entity refers to one or moreof that entity. As such, the terms “a” (or “an”), “one or more” and “atleast one” can be used interchangeably herein. It is also to be notedthat the terms “comprising”, “including”, and “having” can be usedinterchangeably.

“Adhesive” generally refers to a composition comprising homopolymers,copolymers or polymer alloy comprising one or more of polyolefins,polystyrenes, polyvinyls, polyacrylics, polyhalo-olefins, polydienes,polyoxides, polyesthers, polyacetals, polysulfides, polythioesters,polyamides, polythioamides, polyurethanes, polythiourethanes, polyureas,polythioureas, polyimides, polythioimides, polyanhydrides,polythianhydrides, polycarbonates, polythiocarbonates, polyimines,polysiloxanes, polysilanes, polyphosphazenes, polyketones,polythioketones, polysulfones, polysulfoxides, polysulfonates,polysulfoamides, polyphylenes, and combinations and/or mixtures thereof.More specifically in a preferred embodiment, the thermoplastic adhesivecomposition comprises one of acrylonitrile butadiene styrene, acrylic(PMMA), celluloid, cellulose acetate, cyclo-olefin copolymer,ethylene-vinyl acetate (EVA), ethylene vinyl alcohol (EVOH),fluoroplastic (PTFE, FEP, PFA, CTFE, ECTFE, and/or ETFE), ionomer,liquid crystal polymer (LCP), polyacetal (POM and/or acetal),polyacrylate (acrylic), polyacrylonitrile (PAN or acrylonitrile),polyamide (PA or nylon), polyamide-imide (PAI), polyaryletherketone(PAEK and/or ketone), polybutadiene (PBD), polybutylene (PB),polybutylene terphthalate (PBT), polycaprolactone (PCL),polychlorotrifluoroethylene (PCTFE), polyethylene terephthalate (PET),polycycloheylene dimethylene terephthalate (PCT), polycarbonate (PC),polyhydroxylalkanoate (PHA), polyketone (PK), polyester, polyethylene(PE), polyetherketoneketone (PEKK), polyetherimide (PEI),polyethersulfone (PES), polysulfone, polyethlenechloriate (PEC),polyimide, polyacetic acid (PLA), polymethylpentene (PMP), polyphenyleneoxide (PPO), polyphylene sulfide (PPS), polyphthalamide (PPA),polypropylen (PP), polystyrene (PS), polsulfone (PSU), polytrimethylenterphthalate (PTT), polyurethane (PU), polyvinyl acetate (PVA),polyvinyl chloride (PVC), polyvinylidene chloride (PVDC),styrene-acrylonitrile (SAN), and combinations thereof. The adhesive maybe one of a thermosetting adhesive, a thermoplastic adhesive, asubstantially A-staged thermosetting adhesive, a substantially B-stagedthermosetting adhesive, a self-supporting adhesive film, a bi-laminateadhesive film having first and second adhesive layers, the firstadhesive layer and second adhesive layer differing in one or both ofchemical composition and physical properties, a tri-laminate adhesivefilm having a polymeric film positioned between a first adhesive filmand a second adhesive film, a fast flow, low-melt adhesive, a hot-meltadhesive; and a combination and/or mixture thereof. Further regardingthe tri-laminate adhesive film, the first adhesive film and secondadhesive film may differ in one or both of chemical composition andphysical properties, or have substantially the same chemical compositionand physical properties, and the polymeric film may comprise one or moreof an elastomeric material, a substantially inelastic material, clear,opaque, colored, uncolored, or a combination thereof. The polymeric filmmay be a tie layer.

“Cutting” and/or “etching” generally refer to any suitable techniqueand/or method, to form one or more of the article and any of thedecorative elements or articles described herein. The article and any ofthe one or more of the decorative elements can be cut before, during,and/or after registering. The cutting process may be any suitablecutting device known to a person of ordinary skill within the art, suchas a steel-rule dies, hard tool metal dies, laser cutter, ultrasoundcutter, high frequency cutter, hot-wire cutter, or water jet cutter.Commonly, the cutting process is one of laser or die cutting process.The cutting and/or etching process may also include ablation.Particularly preferred laser cutting, etching and/or ablation processesare disclosed in U.S. application Ser. No. 11/874,146 to Abrams, whichis incorporated in its entirety herein by this reference. Laser cuttingand/or etching are preferred in applications where discoloration is notan issue. Laser cutting and/or etching can seal and/or fuse the cutedges. Moreover, laser cut and/or etched edges can be one or both ofsmooth and level. Laser power and speed of the cutting and/or etchingprocesses commonly affect the degree that cut-edges are one or more offused, smooth, and level. Furthermore, laser power and speed of thecutting and/or etching process typically affects the degree that the cutedges are substantially free of waviness, sagging and charring. Forexample, low laser power and/or fast cutting speed can increase thedegree of charring. Optimal cutting and/or etching typically requires abalancing of the laser power and line speed to form sharp, clean cutedges. Sharp, clean cut edges are more difficult to achieve bydie-cutting, particularly at line speeds equivalent to those achievableby laser cutting and/or etching. Furthermore, the dies need to beroutinely replaced and/or sharpened. Commonly, a cutting machine havingan optical element to identify a selected reference point, such as whenregistering is performed in conjunction with cutting and/or etching. Thereference point may be identified optically, for example, usingreflected laser light in a conventional laser light registration system,as known by those of skill in the art. Optical registration is preferredover using a guide side (or a prior cut line) because some materialslack sufficient dimensionality to use an edge for registration. Once thedesired reference point is identified, the cutting and/or etchingelement cuts and/or etchs out the design image using programmed logic toimpart accurate registration and to precisely cut out and/or etch one ormore of the decorative articles and any one or more of the decorativeelements described herein.

“Elastomeric polymeric materials,” “elastomeric polymers,” and“elastomeric materials” generally refer to one or more of rubbers,polyisoprenes, polybutadinenes, styrene-butadienes, chloroprenes,ethylene propylene rubbers, ethylene-vinyl acetates, ethylene propylenediene rubbers, polyacrylic rubbers, epichlorohydrin rubbers,fluorosilicones, fluoroelasters, silicones, perfluoroelastomers,polyether block amides, chlorosulfonated polyethylenes and combinationsthereof). Non-limiting examples of stretchable andelastic-knits/stretchable and elastic-weaves are sprang waves,mesh-weaves, open weaves, warp knits, and two-way knits. While notwanting to be limited by example, suitable stretchable andelastic-knits/stretchable and elastic-weave textile materials areLycra™, Spandex™, 4-, 3-, 2-, or 1-way stretch fleece fabrics, andstretch cotton weaves (such as, stretch rayon jersey knit and/orcotton/LYCRA™ combinations).

“Knit” generally refers to a fabric having a series of connected loops.The loops formed in the knitting process are generally made byintertwining yarn, thread, or strips in a series of consecutive loops,called stitches. As each row progresses, a new loop is pulled through anexisting loop. The loops are generally easily stretched in differentdirections. Knitting normally uses one set of yarn, which is workedeither horizontally or vertically, not both. Knitting typically has tworecognized knitting structures, namely warp and weft knitting. Warpknitting has one set of yarn for each wale, each yarn travellingvertically. Weft knitting has one set of yarn, which travelshorizontally across the fabric. The knitted textile can be formed by anyknitting process, including but not limited to weft knitting (in whichthe wales are substantially perpendicular to the course of the yarn),warp knitting (in which the wales and courses are roughly parallel toeach other), knit stitch, purl stitch, stockinette, reverse stockinette,garter stitch, seed stitch, right-plaited stitches, left-plaitedstitches, flat knitting, circular knitting, a single yarn knit, aplurality of yarns knit, a double knit textile, an uneven knit, a shadowknit, a fair-isle knit, a plaited knit, flat knitting, circularknitting, or felt knitting. Examples of possible knit patterns orconstructions include knits and purls, reversible stitch patterns,eyelets and lace, mosaic stitch patterns, multi-color stitch patterns,and the like. Specific examples of patterns include basketweave,basketweave II, box stitch, broken rib, cable stitch, casting on,casting off, checks and ridges, chevron, close checks, decrease,diagonal rib, diagonals, diamond pattern, double basket weave, doubleseed stitch, elongated chevron, embossed diamonds, embossed moss rib,garter rib, garter stitch, garter stitch steps, increase, Invernessdiamonds, King Charles brocade, knit stitch, large diamonds, littlepyramids, mistake rib, mock cable, moss diamonds, moss panels, mossstitch, moss stitch border diamonds, moss stitch parallelograms,parallelograms, parallelograms II, pavilion, pique triangles, plaindiamonds, purl stitch, purled ladder, rib stitch, rice stitch, seedstitch, single chevron, slip stitch, spaced checks, squares, squares insquares, stocking stitch, thermal underwear stitch, triangles, triangleribs, triangle squares, triangles, twin rib, two by two rib, windmill,woven stitch, yarn over, and combinations thereof. A preferreddecorative element has knit and purl stitches arranged substantiallysymmetrically (such as in ribbing, garter stitch, or seed stitch) sothat the decorative element lies substantially flat.

“Laser engraving”, “laser marking”, “laser cutting” and/or “laseretching” refer to using lasers to engrave, mark, cut or etch an object.The technique does not generally involve the use of chemicals (such as,inks or corrosive materials), nor does it generally involve tool bits,which contact the engraving surface and wear out. These propertiesdistinguish laser engraving cutting, and/or etching from alternativeengraving etching, or marking technologies where inks or bit heads haveto be replaced regularly. The impact of laser engraving and/or etchinghas been more pronounced for specially-designed “laserable” materials.These include laser-sensitive polymers and novel metal alloys. The terms“laser marking” and “laser etching” are also used as a generic termcovering a broad spectrum of surfacing techniques including printing,hot-branding and laser bonding. The machines for laser engraving, laseretching, laser cutting, and laser marking are commonly the same, so thatthe terms are usually interchangeable. A laser engraving machinecommonly includes three main parts: a laser, a controller, and asurface. The point where the laser (the terms “laser” and “laser beam”may be used interchangeably) touches the surface should be on the focalplane of the laser's optical system, and is usually synonymous with itsfocal point. The energy delivered by the laser changes the surface ofthe material under the focal point. It may heat up the surface andsubsequently vaporize the material, or perhaps the material may fracture(known as “glass” or “glass up”) and flake off the surface.

The term “means” as used herein shall be given its broadest possibleinterpretation in accordance with 35 U.S.C., Section 112, Paragraph 6.Accordingly, a claim incorporating the term “means” shall cover allstructures, materials, or acts set forth herein, and all of theequivalents thereof. Further, the structures, materials or acts and theequivalents thereof shall include all those described in the summary ofthe invention, brief description of the drawings, detailed description,abstract, and claims themselves.

A “metalized material” generally refers to one or more of a polymericcomposition-containing metalized particles, a polymeric compositionhaving a metalized coating, a polymeric composition having a metalizedappearance, a metal-containing composition, and a combination and/ormixture thereof. The metalized material may comprise a moldedpolyurethane or silicone. Typically, the metalized material comprisesmolded polyurethane formed by high-frequency molding and/or shapingprocesses. More typically, the metalized material comprises moldedmetal-containing polyurethane formed by high-frequency molding and/orshaping processes. The high frequency molding process is commonly aradio frequency molding process. The molded polyurethane may have asingle metallic hue. The metal may be any metal. Generally, the metal issilver, nickel, aluminum, or alloys and combinations thereof. The metalmay be encapsulated and/or dispersed in the polymeric material. Themetal may be coated to provide for additional and/or different hues. Forexample, the metal can be coated with yellow hue to provide for agold-like look, or dark orange for copper-like look. Commonly, the metalmay be encapsulated and/or dispersed in the polyurethane. While notwanting to be limited by example, the metal may be encapsulated and/ordispersed between two polymeric film layers. The metalized material mayor may not include an adhesive layer. The metalized material typicallyhas a metallic surface or metallic-like appearing surface and anopposing surface. The opposing surface may or may not include theadhesive layer. The adhesive layer can be in the form of an adhesivefilm layer. The metallic-appearing surface is commonly in the form ofthree-dimensional surface. The three-dimensional surface is formedduring the high frequency molding process. Furthermore, edges of themetalized material can formed during the molding process. That is, theedges may be formed using a combination of high frequency energy and/orheat. Furthermore, the edges may be formed during the molding process bythe mold die, specifically by the edge of the mold die and the pressureapplied during the molding process. The molding process may or may notinclude welding a textile base to metalized material. Commonly, themetalized material is provided without a textile base. However, whenprovided with a textile base, the textile base is part of the metalizedmaterial. That is, the textile base of the metalized material is not adecorative element as used herein, other than that of the metalizedmaterial the textile base is molded thereto. The high frequency moldingcannot cut through flock fibers, such as nylon flock fibers, nor throughtypical textile materials such as polyester-containing textilematerials. More specifically, the high frequency molding process cannotcut through polymeric materials having a melting point greater thannylon and/or polyester. Even more specifically, the textile base has amelt temperature of commonly no more than about 190 degrees Celsius,more commonly no more than about 180 degrees Celsius, even more commonlyno more than about 170 degrees Celsius. The metalized material can beone or more of pliable, soft and washable. More specifically, themetalized material can be laundered with clothing. The metalizedmaterial can be fabricated to resemble a metallic badge, such as, apolice officer's badge, a fire department badge, a federal agent's badgeor such.

“Polymer” or “polymer composition” generally refers to a moleculecomprising a plurality of repeating chemical groups, typically referredto as monomers. Polymers include man-made polymers, natural polymers andmixtures thereof. Polymers are often characterized by high molecularmasses. Useful polymers include organic polymers and inorganic polymersboth of which may be in amorphous, semi amorphous, crystalline,partially crystalline states, or combinations thereof. Polymers maycomprise monomers having the same chemical composition or may comprise aplurality of monomers having different chemical compositions, such as acopolymer. Cross-linked polymers have linked monomer chains. Usefulpolymers include but are not limited to plastics, elastomers,thermoplastic elastomers, elastoplastics, thermosets, thermoplastics andacrylates. Exemplary polymers include but are not limited to acetalpolymers, biodegradable polymers, cellulosic polymers, epoxies,fluoropolymers, polyolefins, polystyrenes, polyvinyls, polyacrylics,polyhalo-olefins, polydienes, polyoxides/esthers/acetals, polysulfides,polyesters/thioesters, polyamides/thioamides,polyurethanes/thiourethanes, polyureas/thioureas, polyimides/thioimides,polyanhydrides/thianhydrides, polycarbonates/thiocarbonates, polyimines,polysiloxanes/silanes, polyphosphazenes, polyketones/thioketones,polysulfones/sulfoxides/sulfonates/sulfoamides, polyphylenes, nylons,polyacrylonitrile polymers, polyamide, imide polymers, polyimides,polyarylates, polybenzimidazole, polybutylene, polycarbonate,polyesters, polyetherimide, polyethylene, polyethylene copolymers andmodified polyethylenes, polyketones, poly(methyl methacrylate),polymethylpentene, polyphenylene oxides and polyphenylene sulfides,polyphthalamide, polypropylene, polyvinyls, polyurethanes, natural andsynthetic rubber, silicones, styrenic resins, sulfone based resins,vinyl based resins and any combinations of these.

A “satin” weave and/or satin textile material generally refers to aflat, smoothly woven type weave, such as, but not limited to satin typeweaves with an interlacing float of at least 2 or to at least thefollowing satin weave types commonly known within the art as:

a) Brocade—A brocade weave is a compound weave where a supplementarywarp or filling yarn is inlaid into a base fabric to produce anembroidered appearance. (The supplementary or filling yarn is a yarnthat can be removed without affecting the base fabric.) Brocade weavescan be continuous where the supplementary yarn floats on the back of thebase fabric and is not visible on the fabric face, or discontinuouswhere the supplementary yarn is woven into the patterned areas visibleon the fabric face.

b) Brocatelle—A brocatelle weave is a highly textured or high-reliefmotif produced with an additional yarn the runs between the fabric faceand back to produce a pronounced texture, or dimensionality, or reliefto the fabric surface. Brocatelle weaves are typically based on, but notlimited to, satin weaves.

c) Camocas—A comocas fabric is typically a stain weave with a diapereddesign.

d) Crepe-back satin, Satin-back crepe, Crepe-satin, or Satin-crepe—Thesefabrics typically comprise a stain weave on the fabric face and a crepecrinkled affect produced by the weave, yarn or finishing technique onthe back of the fabric. Typically weft crepe yarns are twisted andoutnumber any supplemental or filling yarn by a factor of at least 2:1.

e) Duchesse—A duchesse weave is a high thread count satin weave,typically woven with fine yarns having a higher density of warp to weftyarns. Duchesse fabrics have a high luster and are highly textured andfirm.

f) Satin—A warped-faced satin weave satin weave is a weave where warpyarns pass over multiple weft yarns before interlacing another waftyarn, or filling-faced satin weave where weft yarns pass over multiplewarp yarns before interlacing another warp yarn. A satin weave producesa fabric surface where the warp and weft intersection points are aswidely spaced as possible. Satins are typically woven with low twistfilament yarns.

g) Double-face satin—A double-face satin has two satin constructions,one on the face and another on the back, produced by a weave having twowarps and one weft.

h) Paillette satin—A paillette stain is a weave that produces achangeable color affect.

i) Peau de soie—A peau de soie stain weave can be of a single or doubleconstruction, typically characterized by a cross-rib texture in the weftdirection and a slight luster.

j) Satin-back—A satin-back fabric is characterized by a weave and/orfabric on one side and any other weave or fabric on the opposing fabricside.

k) Satin foaconne—A stain foaconne is a slightly creped fabric withsmall designs.

l) Slipper satin—A slipper satin is a compact satin that can bebrocaded.

m) Velvet satin—A velvet satin comprises a warp-pile satin weave with ashort, dense cut pile. The pile consists of a looped yarn on the fabricsurface; the loop can be produced by: 1) knotting the yarn at the baseof the fabric; 2) weaving the yarn over wires to produce loops at thebase of the fabric and cutting the loops to produce a cut pile; or 3)weaving the warp yarn to produce a double cloth and slicing the warpyarns positioned between the two opposing cloth surfaces to produce twocut-pile fabrics.

“Spacer” generally refers to any material positioned below a decorativeelement. The spacer is generally adhered to the decorative element by anadhesive, such as but not limited to a hot melt adhesive. The spacer isgenerally smaller than the decorative element. The spacer can provideone or more of: substantially decreases, or eliminates, adhesion of theadhesive to an uneven/textured substrate and the decorative element;substantially decrease, or eliminates, telegraphing of theuneven/textured substrate surface to the decorative element; createssome rigidity and/or integrity to the decorative element so that it isone or both of substantially smooth and flat; creates some space betweenthe uneven/textured substrate surface and the decorative element toprovide one or both of a substantially smooth and flat decorativeelement. The spacer creates a “buffer space” between the decorativeelement and the uneven/textured substrate.

“Substrate” generally refers to any article to be decorated. Thesubstrate may comprise any material. Non-limiting examples of suitablesubstrates comprise metallic materials, synthetic or natural polymericmaterials, glass-based materials, ceramic materials, leather-basedmaterials and combinations thereof and may or may not be stretchableand/or have elastic properties. The substrate may comprise an item ofapparel, typically a stretchable, elastic, and/or bendable item ofapparel. Non-limiting examples of stretchable and elastic items ofapparel are jerseys, leotards, pants, shirts, blouses, leggings, socks,shoes, under garments, and accessories (such as, but not limited to,hair-bands, wrist bands, head bands, finger bands, ankle bands, fingerbands, toe-bands, arm bands, and shoe-laces). The substrate may have asingle surface or a plurality of surfaces. Non-limiting examples of asingle-surfaced substrate are articles having one of a generallyspherical, circular-donut, and elliptical-donut shapes. Non-limitingexamples of substrates having a plurality of article surfaces arearticles substantially resembling one of a cube, rectangular-box andtetrahedral shapes. The substrate can include one of a hook or loopcomponent of a hook and loop attachment system.

“Textile material” generally refers to one of: a woven textile material;a knitted textile material; a non-woven, non-knitted textile material; asubstantially elastomeric textile material; a substantiallynon-elastomeric textile material; and a combination and/or mixturethereof. The textile material can be a suede-like fabric. Moreover, thetextile material can be a microfiber textile material.

“Woven” generally refers to a fabric comprising at least two sets ofyarn, thread, or strips, one warp (longitudinal) and one filling yarn,thread, or strip (transverse or crosswise), normally laced atsubstantially right angles to each other. Commonly, the yarn, thread, orstrips are straight, run parallel either lengthwise (warp threads) orcrosswise (weft threads). The weft yarn is commonly interlocked with thewarp by passing under then over, one or more warp threads. Elasticitycan be increased in woven fabrics when they are woven from yarncontaining elastomeric yarn such as elastane (Lycra® from Invista orDorlastan® from Bayer).

Unless otherwise noted, all component or composition levels are inreference to the active portion of that component or composition and areexclusive of impurities, for example, residual solvents or by-products,which may be present in commercially available sources of suchcomponents or compositions.

All percentages and ratios are calculated by total composition weight,unless indicated otherwise.

It should be understood that every maximum numerical limitation giventhroughout this disclosure is deemed to include each and every lowernumerical limitation as an alternative, as if such lower numericallimitations were expressly written herein. Every minimum numericallimitation given throughout this disclosure is deemed to include eachand every higher numerical limitation as an alternative, as if suchhigher numerical limitations were expressly written herein. Everynumerical range given throughout this disclosure is deemed to includeeach and every narrower numerical range that falls within such broadernumerical range, as if such narrower numerical ranges were all expresslywritten herein.

The preceding is a simplified summary of the disclosure to provide anunderstanding of some aspects of the disclosure. This summary is neitheran extensive nor exhaustive overview of the disclosure and its variousaspects, embodiments, and configurations. It is intended neither toidentify key or critical elements of the disclosure nor to delineate thescope of the disclosure but to present selected concepts of thedisclosure in a simplified form as an introduction to the more detaileddescription presented below. As will be appreciated, other aspects,embodiments, and configurations of the disclosure are possibleutilizing, alone or in combination, one or more of the features setforth above or described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated into and form a part of thespecification to illustrate several examples of the present disclosure.These drawings, together with the description, explain the principles ofthe disclosure. The drawings simply illustrate preferred and alternativeexamples of how the disclosure can be made and used and are not to beconstrued as limiting the disclosure to only the illustrated anddescribed examples. Further features and advantages will become apparentfrom the following, more detailed, description of the various aspects,embodiments, and configurations of the disclosure, as illustrated by thedrawings referenced below.

FIG. 1 depicts a cross-sectional view of an article according to someaspects of the present disclosure;

FIG. 2 depicts a cross-sectional view of an article according to someaspects of the present disclosure;

FIG. 3A is an elevation plan view of an article according to someaspects of the present disclosure;

FIG. 3B is a cross-sectional view of FIG. 3A;

FIG. 4 depicts a process according to some aspects of the presentdisclosure;

FIG. 5 depicts a cross-sectional view of a decorative element accordingto some aspects of the present disclosure;

FIG. 6 depicts a cross-sectional view of a decorative article accordingto some aspects of the present disclosure;

FIG. 7 is an elevation plan view of a decorative article according tosome aspects of the present disclosure;

FIG. 8 depicts a cross-sectional view of a decorative article accordingto some aspects of the present disclosure;

FIG. 9 depicts a cross-sectional view of a decorative article accordingto some aspects of the present disclosure; and

FIG. 10 is an elevation plan view of a decorative article according tosome aspects of the present disclosure.

DETAILED DESCRIPTION

FIG. 1 depicts a cross-sectional view of a decorative article 100according to various embodiments. The decorative article 100 includes afirst layer 101 adhered a second layer 102. The first 101 and second 102layers may be directly adhered to one another or may be adhered to oneanother by an adhesive (not depicted).

FIGS. 2, 3A and 3B depict decorative articles 100 having one or morevoids 105 in the first layer 101. In some configurations, a firstportion of the second layer surface 104 is visible, to a person viewingthe decorative article 100, within the one or more voids 105. The one ormore voids 105 can be in the form of apertures having a depth “D” (FIGS.2 and 3B). Typically, the one or more voids 105 are in the form ofalphanumeric characters, graphic design images, or combination thereof.For example, the alphanumeric characters can in the form of lettersand/or numbers and the graphic design images can be form of a mascot,company logo, geographic area, or professional insignia to name a few.FIG. 3A depicts an elevation plane view of decorative article 100 havingthe one or more voids 105 in form of alphanumeric characters, and FIG.3B depicts a cross-sectional view of FIG. 3A along line 3B-3B. Morespecifically, FIGS. 3A and 3B depict configurations having the secondlayer surface 104 visible within the one or more voids 105 to personviewing upper surface 199 of the decorative article 100.

Generally, laser engraving and/or cutting forms the one or more voids105. That is, the first layer 101 can be etched and/or cut with a laserto form the one or more voids 105. The one or more voids 105 have voidwalls 188. Commonly, the first layer 101 has a sufficiently high meltand/or softening temperature so that when the first layer 101 is laseretched and/or cut the void walls 188 are formed with a substantiallysmooth and level wall surface. That is, the void walls 188 aresubstantially devoid of waves or sags in the wall surface. While notwanting to be limited by theory, it is believed that having a firstlayer 101 with a sufficiently high melt and/or softening temperaturesthe void walls 188 do not substantially sag during and/or after thelaser etching and/or cutting. Furthermore, the sufficiently high meltand/or softening temperatures provide for substantially sharplydelineated void walls 188. Moreover, the void walls 188 aresubstantially free of char after being formed by the laser cuttingand/or etching process. It can be appreciated that in some embodiments,the first layer 101 can be one or more of molded with the one or morevoids 105 or die-cut to form the one or more voids.

FIG. 4 depicts process 200 for making decorative article 100.

In step 210, a decorative article intermediate is provided for one orboth of laser etching and/or laser cutting. The decorative articleintermediate can be a first layer 101 adhered to a second layer 102(FIG. 1) or the first layer 101 alone (that is, with a second layer 102not adhered to the first layer 101). The decorative article intermediateprovided on step 210 can be free of voids 105 or can have voids 105formed by methods other than laser etching and/or cutting, such as bymolding and/or die-cutting.

In step 220, the decorative article intermediate is registered with alaser etching and/or cutting system. The registration can be amechanical registration, optical registration, electro-mechanicalregistration, computerized registration, or a combination thereof. Thedecorative article intermediate is generally to liner base sheet havinga low surface energy. The liner base sheet can comprise silicone andTEFLON™. The liner base sheet substantially acts as “release” sheet forholding the decorative article intermediate in place of steps 220 and230. More specifically, the liner base sheet adheres the decorativearticle intermediate in position with light handling and easily andcleanly releases the decorative article intermediate when pulled apart.

In step 230, the decorative article intermediate is sequentially etchedand/or cut by the laser system. Some of the material comprising thedecorative article intermediate is removed by the sequential etchingand/or cutting of decorative article intermediate. A laser beam isgenerated by the laser system. The laser beam is contacted inregistration with the decorative article intermediate. The contacting ofa laser beam with the decorative article intermediate removes at leastsome of the material comprising the decorative article intermediate. Thecontacting of the laser beam sequentially with the decorative articleintermediate removes some of material contained in the one or more voids105 to be formed. The sequential process of contacting the laser beamwith decorative article intermediate is continued until substantiallyall of the decorative article material contained within the one or morevoids 105 is removed by the laser etching and/or cutting process.Typically, the contacting of the laser beam with the decorative articleintermediate vaporizes at least some of the material contained in theone or more voids 105. When the decorative article intermediatecomprises a first layer 101 adhered to a second layer 102, thedecorative article 100 is formed by the sequential contacting of thelaser beam with the decorative intermediate to create the one or morevoids 105.

Typically, one or more sequential passes of the laser beam forms the oneor more voids 105. It can be appreciated that a single pass of the laserbean can include one or more laser pulses. It can be appreciated thateach sequential pass of the laser beam comprises contacting of the laserbeam with the decorative article intermediate.

Generally, each pass of the laser beam in the sequential laser etchingand/or cutting process removes more than about 0.5% of the decorativearticle intermediate material contained in the one or more voids 105.More generally, the each pass of the laser beam removes from about 0.5to about 1% of the material contained the one or more voids 105. Evenmore generally, each pass of the laser bean removes from about 1% toabout 5%, yet even more generally from about 5 to about 10%, still yeteven more generally from about 10% to about 20%, still yet even moregenerally from about 15 to about 30%, still yet even more generally fromabout 25 to 40%, still yet even more generally from about 30 to about50%, or yet still from about 45 to about 100% of the decorative articleintermediate material contained in the one or more voids 105.

Typically, the sequential etching and/or cutting of decorative articleintermediate comprises no more than twelve sequential passes of thelaser beam. However, in some embodiments the sequential etching and/orcutting of the decorative article intermediate comprises more thantwelve sequential passes of the laser beam.

The laser etching and/or laser cutting comprises a sufficient laser beamenergy level and a sufficient number of passes of laser beam to removethe decorative article intermediate material contained in the one ormore voids 105, but little, if any, of the second layer material 102,when the second layer 102 is present during the laser etching and/orlaser cutting process.

Regarding optional step 240, this step is included when the decorativearticle intermediate comprises the first layer 101 without a secondlayered adhered thereto, the optional step 204 comprises adhering thesecond layer 101 to the laser etched and/or cut first layer 101.

The first layer 101 may or may not have a metallic appearance. The firstlayer 101 can be opaque. Typically, the second layer 102 is visiblewithin the one or more voids 105, but not visible through an opaquefirst layer 101. It can be appreciated that in some embodiments thefirst layer 101 can have some level of transparency. In suchembodiments, the second layer 102 may or may not be visible through thetransparent first layer 101. Moreover, the appearance of the secondlayer 102 in the one or more voids 105 may or may not differ from theappearance of the second layer 102 through the transparent first layer101. For example, the transparent first layer 101 can have a color ormetallic appearance that affects the appearance of the second layer 102when viewed through the transparent first layer 101. While not wantingto be bound by theory, the second layer 102 may have a yellow color andthe transparent first layer 101 a blue color. In such an instance, thesecond layer 102 in the one or more voids 105 would appear to a viewerto be yellow, but the blue first layer 101 would appear green due tounderlying yellow second layer 102.

Typically, the first layer 101 has a metallic appearance. In someembodiments, one or both of the first 101 and second 102 layers have asubstantial metallic appearance. The first layer 101 has opposing upper199 and lower 198 surfaces. The lower surface 198 is, when the first 101and second 102 layers are stacked, positioned adjacent to the secondlayer 102. In some embodiments, the upper surface 199 can have asubstantially, smooth flat surface. Furthermore, the upper surface 199can be a dimensionalized surface having three-dimensional profile.

The decorative article 100 can be substantially flexible. That is, thedecorative article 100 when adhered to an item of apparel (such as ashirt, jacket, jersey, leggings, pants, or such) can substantially bendand/or flex with the item of apparel during normal activity.

The decorative article 100 can be substantially light-weight andflexible. Metals typically have a density of about 2 g/cm³ or more.Generally, the decorative article of 100 has a metallic appearance and adensity of no more than about 1.5 g/cm³, more generally a density of nomore than about 1.3 g/cm³, even more generally a density of no more thanabout 1.2 g/cm³, yet even more generally a density of no more than about1.1 g/cm³, still yet even more generally a density of no more than about1.0 g/cm³, more generally, or yet still even more generally a density ofno more than about 0.9 g/cm³.

Metals generally have a tensile strength of greater than about 10⁸Pascals. Typically, the decorative article 100 has the appearance of ametal and a tensile strength of no more than about 10⁷ Pascals, moregenerally no more than about 10⁶ Pascals or even more generally no morethan about 10⁵ Pascals.

Metals commonly have a modulus of elasticity or flex strength greaterthan about 10¹⁰ Pascals. Typically, the decorative article 100 has theappearance of a metal and a modulus of elasticity or a flex strength ofno more than about 10⁹ Pascals, more generally no more than about 10⁸Pascals, even more generally no more than about 10⁷ Pascals, or yet evenmore generally no more than about 10⁶ Pascals.

The first layer 101 can be a decorative metalized film. While notwanting to be limited by example, the decorative metalized film can be amolded metalized film. In one configuration, the decorative metalizedfilm comprises a metal-interposed multi-layer thermoplastic syntheticresin film as described in one or more of U.S. Pat. Nos. 8,110,059;5,589,022; 5,677,037; 5,599,416; 5,520,988; and 5,143,672, each of whichis incorporated in its entirety herein by this reference. It can beappreciated that, the first layer 101 can be one or more of a metalfilm, a metal film adhered to polymeric film, a polymeric film having ametal distributed throughout the polymeric material, a bi-component filmhaving a polymeric film substantially devoid of metal adhered topolymeric film having a metal distributed throughout the polymeric film,a polymeric film material having three or films adhered together and oneof the three is one of a metal film or a polymeric film having a metaldistributed throughout the polymeric film, or a combination thereof. Insome embodiments, the first layer can be an intermetallic alloy orenamel.

It some configurations, the first layer 101 can comprise one or moremetalized layers stacked one on top of another. Moreover, the secondlayer 102 can be adhered to the first layer 101 having one or moremetalized layers stacked one on top of another. The first layer 101 canhave a texturized surface. The texturized surface can vary in patternand/or form over the surface of the first layer 101.

In some embodiments, the first layer 101 can comprise an organicpolymeric composition. The organic polymeric composition may or may notcontain a metallic material or a material that imparts a metallicappearance to the organic polymeric composition. The organic polymericcomposition can be one of polyurethane, polyester and combinationthereof.

The organic polymeric composition can comprise a sublimation printablepolymeric composition. The sublimation printable polymeric compositioncan be an organic polymeric sheet material capable of acceptingsublimation dyes. While not wanting to be limited by example, thesublimation printable polymeric composition can comprise a polyester,polyester copolymer, polyester polymer alloy, polyester polymer blend ora combination thereof.

Generally, the sublimation printable polymeric composition issubstantially free of one or both of poly(cyclohexylene-dimethyleneterephthalate) and poly(1,4-cyclohexylene-dimethylene terephthalate).More generally, the sublimation printable polymeric composition containsno more than about 1 wt %, even more generally no more than about 0.5 wt%, or yet even more generally no more than about 0.1 wt % of one or bothof poly(cyclohexylene-dimethylene terephthalate) andpoly(1,4-cyclohexylene-dimethylene terephthalate). Typically, thesublimation printable polymeric composition is substantially devoid ofpoly(cyclohexylene-dimethylene terephthalate) andpoly(1,4-cyclohexylene-dimethylene terephthalate).

The sublimation printable polymeric composition can be one of a rigid orsemi-rigid polymeric sheet material. The sublimation printable sheet canbe a rigid or semi-rigid, white polymeric material. The sublimationprintable sheet material can comprise a first polymer and a secondpolymer. In accordance with some configurations, one or both of thefirst and second polymers can comprise polyester. According someembodiments, the first and second polymers, respectively, have first andsecond softening temperatures and first and second melt temperatures.The second softening temperature is greater than the first softeningtemperature and the second melt temperature is greater than the firstmelt temperature. Commonly, the second softening temperature is morethan 50 degrees Fahrenheit greater than the first softening temperature,more commonly more than 100 degrees Fahrenheit greater than the firstsoftening temperature, even more commonly more than 150 degreesFahrenheit greater than the first softening temperature, or yet evenmore commonly more than about 200 degrees Fahrenheit greater than thefirst softening temperature. Typically, the second softening temperatureis more than 50 degrees Fahrenheit greater than the first meltingtemperature, more typically more than 100 degrees Fahrenheit greaterthan the first melting temperature, even more typically more than 150degrees Fahrenheit greater than the first melting temperature, or yeteven more typically more than about 200 degrees Fahrenheit greater thanthe first melting temperature. While not wanting to be limited bytheory, at least one of first or second polymers generally has a melt orsoftening temperature of more than about 350 degrees Fahrenheit, moregenerally a melt or softening temperature of more than about 375 degreesFahrenheit, even more generally a melt or softening temperature of morethan about 400 degrees Fahrenheit, yet even more generally a melt orsoftening temperature of more than about 425 degrees Fahrenheit, orstill yet even more generally a melt or softening temperature of morethan about 450 degrees Fahrenheit.

Generally, the first and second polymers are substantially free of oneor both of poly(cyclohexylene-dimethylene terephthalate) andpoly(1,4-cyclohexylene-dimethylene terephthalate). More generally, theindividually or together the first and second polymers contain no morethan about 1 wt %, even more generally no more than about 0.5 wt %, oryet even more generally no more than about 0.1 wt % of one or both ofpoly(cyclohexylene-dimethylene terephthalate) andpoly(1,4-cyclohexylene-dimethylene terephthalate). Typically, the firstand second polymers are substantially devoid ofpoly(cyclohexylene-dimethylene terephthalate) andpoly(1,4-cyclohexylene-dimethylene terephthalate).

It is believed that having a sublimation printable polymeric compositioncomprising a polymer having a softening temperature of more than about350 degrees Fahrenheit can substantially improve the sublimation printedimage quality. For example, the sharper images and/or finer, sharperlines can be sublimated printed on polymeric compositions and/orpolymeric sheet materials having a softening temperature more than about350 degrees Fahrenheit compared to polymeric sheet materialssubstantially lacking a polymer having a softening temperature of morethan about 350 degrees Fahrenheit.

The organic polymeric composition can be in the form of a sublimationprintable polymeric coating. A glossy clear film can be applied to thesublimation printable polymeric coating. Furthermore, the glossy clearfilm can be positioned on the printable polymeric coating surface.

The organic polymeric composition can contain a sublimation printedimage. Typically, the sublimation printed image quality of the organicpolymeric composition is substantially superior to the sublimation dyeprint quality on textiles, flock, or other free standing polymericfilms. The sublimation dye printed image on the organic polymericcomposition is one or more of substantially sharper, clearer, andcleaner with more true and vibrant color then sublimation dyed printedimages on textiles or other polymeric films.

FIG. 5 depicts a first layer 101 having one of metalized film, anorganic polymeric composition, a sublimation printable polymericcomposition, or combination thereof layer 166 interposed between upper161 and lower 162 optically transmissive layers. At least most of thevisible light portion of the electromagnetic spectrum can be passed bythe upper 161 and lower 162 optically transmissive layers. Typically,the upper 161 and lower 162 optically transmissive layers comprisethermoplastic synthetic resin films. A color-enhancing layer 165 can bepositioned between the upper 161 and lower 162 optically transmissivelayers. The color-enhancing layer 165 can be, for example, a translucentcolor-containing ink layer. Moreover, the color-enhancing layer 165 cancontain one or more additional coats of a clear optically transmissiveink. A non-limiting example of a color-enhancing layer 165 is atranslucent colored-ink printed over a metalized base film, such assilver metalized base film. It can be appreciated that the perceivedvalue of the decorative article 100 is substantially enhanced when thecolor reflected back to a viewer is enriched by the of brilliance of thereflected metallized color. Furthermore, one or both of the upperoptically transmissive layer 161 and one or more additional coats of theclear optically transmissive ink on the color-enhancing layer protectthe color components of the first layer 101 from damage and/ordegradation.

It can be appreciated that in some embodiments, the one of metalizedfilm, an organic polymeric composition, a sublimation printablepolymeric composition, or combination thereof layer 166 is positionedbetween upper optically transmissive layer 161 and the color-enhancinglayer 165, and the color-enhancing layer 165 is positioned between thelower optically transmissive layer 162 and the one of metalized film, anorganic polymeric composition, a sublimation printable polymericcomposition, or combination thereof layer 166. Furthermore, in someembodiments, the color-enhancing layer 165 is positioned between upperoptically transmissive layer 161 and the one of metalized film, anorganic polymeric composition, a sublimation printable polymericcomposition, or combination thereof layer 166, and the one of metalizedfilm, an organic polymeric composition, a sublimation printablepolymeric composition, or combination thereof layer 166 is positionedbetween the lower optically transmissive layer 162 and thecolor-enhancing layer 165.

The second layer 102 can comprise one of an adhesive layer, a woventextile, a knitted textile, or a polymeric layer. The polymeric layercan be one or more of a metal layer, a metal layer adhered to polymericlayer, a polymeric layer having a metal distributed throughout thepolymeric layer, a two-layer film having a polymeric layer substantiallylacking a metal adhered to a polymeric layer having a metal distributedthroughout the polymeric layer, a layered-material having three or morelayers adhered together and at least one of the layers is one of a metallayer or a polymeric layer having a metal distributed throughout thepolymeric layer, intermetallic alloy, enamel, or a combination thereof.

The second layer 102 can comprise one of a thermoplastic adhesive layer,a thermosetting adhesive layer, or an adhesive layer havingthermoplastic and thermosetting adhesive properties. The thermosettingadhesive layer can be one of an A-stage thermosetting adhesive layer, aB-stage thermosetting adhesive layer or a C-staged thermosettingadhesive layer. The adhesive layer can be a hot melt adhesive. Theadhesive layer can comprise in the form of single adhesive layer, abi-layered adhesive or a tri-layered adhesive. The bi-layered adhesivecan comprise a first adhesive stacked on a second adhesive. Thetri-layered adhesive can comprise a metal or polymeric sheet positionedbetween first and second adhesive layers. The first and second adhesivelayers in the bi-layered adhesive and tri-layered adhesive can differ inchemical and/or physical properties or can have substantially similarchemical and/or physical properties.

The adhesive composition comprising the adhesive layer can have at oneor both of its softening and melt temperatures a substantially highviscosity. In the absence of shear force, the adhesive composition atone or both of its softening and melt temperatures can havesubstantially little, if any, flow.

The second layer 102 can comprise a polyester composition. Furthermore,the second layer 102 can comprise a polyester material containing one ormore dyes, pigments, or combinations thereof. The one or more dyes,pigments, or combination thereof can impart a color to the polyestercomposition. The second layer 102 can have a color and/or color valuethat differs from the color and/or color value of the first layer 101.More specifically, the color and/or color value of the second layer 102can differ from the color and/or color value of the first layer 101.Even more specifically, the color and/or color value of the first layer101 can contrast with the color and/or color value of the second layer102.

The second layer 102 can comprise a polyurethane composition.Furthermore, the second layer 102 can comprise a polyurethane materialcontaining one or more dyes, pigments, or combinations thereof. The oneor more dyes, pigments, or combination thereof can impart a color to thepolyurethane composition. The second layer 102 can have a color and/orcolor value that differs from the color and/or color value of the firstlayer 101. More specifically, the color and/or color value of the secondlayer 102 can differ from the color and/or color value of the firstlayer 101. Even more specifically, the color and/or color value of thefirst layer 101 can contrast with the color and/or color value of thesecond layer 102.

FIG. 6 depicts decorative article 100 having a second layer 102 furthercomprising an optically transmissive layer 167. The transmissive layer167 positioned adjacent to the first 101 layer. At least most of thevisible light portion of the electromagnetic spectrum can be passed bythe optically transmissive layer 167. Typically, the opticallytransmissive layer 167 comprises a thermoplastic synthetic resin film.Furthermore, the optically transmissive layer 167 can include acolor-enhancing layer 168 positioned between the optically transmissivelayer 167 and second layer 102. The color-enhancing layer 168 can be,for example, a translucent color-containing ink layer. Moreover, thecolor-enhancing layer 168 may contain one or more additional coats of aclear optically transmissive ink. A non-limiting example of acolor-enhancing layer 168 is a translucent colored-ink printed over ametalized base film, such as silver metalized base film. It can beappreciated that the perceived value of the decorative article 100 issubstantially when the enhanced when the color reflected back to aviewer is enriched by the brilliance of the reflected metallized color.Furthermore, one or both of the optically transmissive layer 167 and oneor more additional coats of the clear optically transmissive inkprotects the color-enhancing layer 168 from damage and/or degradation.It can be appreciated that in some embodiments, the opticallytransmissive layer 167 positioned between upper layer 101 and thecolor-enhancing layer 168, and the color-enhancing layer 168 ispositioned between the second layer 102 and the optically transmissivelayer 167. Furthermore, in some embodiments, the color-enhancing layer168 is positioned between upper layer 101 and the optically transmissivelayer 167, and the optically transmissive layer 167 is positionedbetween the color enhancing layer 168 and the second layer 102.

It can be appreciated that one or both of the optically transmissivelayer 167 and the color enhancing layer 168 may or may not have adhesiveproperties. In some embodiments, the optically transmissive layer 167has adhesive properties. In some embodiments, the color enhancing layer168 has adhesive properties. Moreover, the optically transmissive layer167 can be heat sealed and/or laminated to the color enhancing layer 168and one of the first 101 and second 102 layers. In some embodiments anadhesive is printed on the optically transmissive layer 167, in thezones where laser etching is not to preformed, to adhere to the colorenhancing layer 168 and one of the first 101 and second 102 layers.Furthermore, the color enhancing layer 168 can be heat sealed and/orlaminated to the optically transmissive layer 167 and one of the first101 and second 102 layers. In some embodiments an adhesive is printed onthe color enhancing layer 168, in the zones where laser etching is notto preformed, to adhere to the optically transmissive layer 167 and oneof the first 101 and second 102 layers.

The decorative article 100 can be heat sealed to a substrate. After theheat sealing of the decorative article 100 to the substrate, thesubstrate is substantially permanently adhered to the decorative article100. The substrate can include any item of commerce. Suitable substratesinclude without limitation apparel, automotive components and elements,electronic components and devices, household items, electrical devicesand components, luggage, personal devices and accessories (such aspurses, wallets, and such), to name a few. Items of apparel can be hats,gloves, shoes, stockings, pants, jackets, jersey, shirts, blouses,coats, neckties, skirts, vests, and so forth. The decorative element 100heat sealed to substrate is substantially wash resistant. That is,decorative article 100 remains substantially adhered to the substrateafter about 100 standard wash cycles.

The one or more voids 105 can be in the form of apertures having a depth“D” (FIGS. 2, 3B, 7, and 8) and/or in the form of one or more raisedborders 107 having a height of “H” (FIGS. 7 and 9). The raised borders107 can define one or more voids 105.

The one or more raised borders 107 can comprise part of the first layer101. The one or more raised borders 107 can define a perimeter 106 ofone or more voids 105. To a person viewing the decorative article 100, afirst portion of the second layer surface 104 may or may not be visiblewithin the void 105. In some configurations, a portion of the firstlayer surface is visible within the one or more voids 105 to personviewing the decorative article 100. Outside of the perimeter 106 isviewable surface 103. The viewable surface 103 may comprise one of asecond portion of the second layer surface, a portion of the first layersurface, a substrate surface (not depicted), or a combination thereof.

An insert 108 can be positioned in some or all of the one or more voids105 define by one or both of the apertures and raised borders 107.Referring to FIGS. 8 and 9, the decorative article 100 can have theinsert 108 positioned in a void 105. In FIG. 9, the insert 108 isadhered by adhesive layer 123 to the raised borders 107 and one of thefirst 101 and second 102 layers. The raised border 107 substantiallysurrounds the insert 108 to hide the adhesive layer 123 and edge of theinsert 108 from view. Furthermore, the adhesive layer 123 and insert 108are substantially protected from wear or damage by the raised border107. Accordingly, the raised border 107 can protect the insert 108 fromdelimitation. The height “H” of the raised border 107 above thesurrounding surface 103 of one of the first 101 and second 102 layers isgenerally at least as high as the collective thickness of the insert 108and adhesive layer 123. In FIG. 8, the insert 108 is adhered by adhesivelayer 123 to the first layer 101 containing the void 105 and to one ofthe first 101 and second 102 layers. The first layer 101 substantiallysurrounds the insert 108 to hide the adhesive layer 123 and edge of theinsert 108 from view. Furthermore, the adhesive layer 123 and insert 108are substantially protected from wear or damage by the first layer 101that surrounds the adhesive layer 123 and insert 108. Accordingly, thefirst layer 101 can protect the insert 108 from delimitation. The depth“D” of the void in the first layer 101 is generally at least as high asthe collective thickness of the insert 108 and adhesive layer 123.

The insert 108 visible to a viewer can be positioned within the one ormore voids with the top surface 122 of insert 108 is substantially flushwith the top surface 121 of the first layer 101 and/or the one or moreraised borders 107 (FIGS. 8 and 9). In such configurations, the insert108 can be adhered to one of the first 101 and second 102 layers by anadhesive 123.

The decorative article 100 can be adhered to an optional backingadhesive (not depicted). The decorative article 100 can be adhered to asubstrate (not depicted) by the backing adhesive.

It can be appreciated that in construction of decorative articles,limitations are imposed by the need to have borders around each color tocontain the color and thereby avoid colors flowing into one another. Thevarious decorative articles 100 of FIGS. 1, 2, 3A, 3B and 5-9 can avoidthis problem by using one or more multi-colored decorative elements asinserts within one or more voids. The decorative element can be formedinto a three dimensional design, such as by thermoforming or etching,thereby providing the decorative element with the desiredthree-dimensional relief. This can obviate the need to have complex andexpensive dies for construction of the decorative element. In otherwords, a blank could be formed as a planar object, with thethree-dimensional relief being provided by the decorative element(s).

The insert 108 and/or first portion of the second layer surface 104visible within the one or more voids 105 can be framed by the firstlayer 101 surrounding the one more voids 105. In some configurations,the insert 108 and/or first portion of the second layer surface 104 ispositioned within the one or more voids 105 and recessed below topsurface 121 of the first layer 101 and/or the one or more raised borders107. The top surface 121 and the insert 108 and/or first portion of thesecond layer surface 104 being visible to the viewer of the decorativearticle 100.

The insert 108 and/or a first portion of the second layer surface 104can comprise a polymerically coated aluminum metal element. Preferably,the polymerically coated aluminum metal element. The polymericallycoated aluminum metal element can comprise a sublimation dye printablepolymeric coating position on and/or adjacent to an aluminum metalsubstrate. The sublimation printable polymeric material is cured andsubstantially permanently adhered to the aluminum metal substrate.Commonly, an insert 108 comprising the polymerically coated aluminummetal element contains a sublimation printed image.

An exemplary polymerically coated aluminum metal element is sold underthe tradename UNISUB® (a registered mark of Universal Woods, Inc.). Itis believed that UNISUB® is polymeric laminate comprises aluminum metalcoated with a polymeric material. The polymeric laminate includessublimation dyeable polymeric coating and a white-colored polymericcoating. The sublimination dyeable polymeric coating is typicallypositioned on at least one surface of the polymerically coated aluminummetal element. More commonly, the sublimination dyeable polymericcoating is typically positioned on opposing surfaces of thepolymerically coated aluminum metal element, even more commonly allsurfaces of the polymerically coated aluminum metal element are coatedwith the sublimination dyeable polymeric coating. The white-coloredpolymeric coating is positioned between the aluminum metal and thesublimation dyeable polymeric coating. A glossy clear film can beapplied to the sublimation dyeable polymeric coating. Furthermore, theclear glossy clear film can be positioned on the dyeable polymericcoating surface opposing the dyeable polymeric coating surface incontact with the white-colored coating. Moreover, the polymeric coatedaluminum metal can be laser cut to any desired shape.

Commonly, the polymerically coated aluminum metal element has athickness of no more than about 10 mm. More commonly, the polymericallycoated aluminum metal element has a thickness of no more than about 9mm, even more commonly of more than about 8 mm, yet even more commonlyof no more than about 7 mm, still yet even more commonly of no more thanabout 6 mm, still yet even more commonly of no more than about 5 mm,still yet even more commonly of no more than about 4 mm, still yet evenmore commonly of no more than about 3 mm, still yet even more commonlyof no more than about 2 mm, still yet even more commonly of no more thanabout 1 mm, still yet even more commonly of no more than about 0.5 mm,still yet even more commonly of no more than about 0.25 mm, still yeteven more commonly of no more than about 0.1 mm, or yet still even morecommonly of no more than about 0.05 mm. In some configurations, thepolymerically coated aluminum element typically has a thickness of morethan about 10 mm.

The polymerically coated aluminum metal element is normallydimensionally stable. That is, the thickness of the polymerically coatedaluminum metal element is substantially sufficient for the aluminummetal element to lie flat, and stay substantially flat during use of thedecorative article 100.

The polymerically coated aluminum metal element is preferably washresistant. That is, the sublimation dye printed image contained inpolymerically coated aluminum metal element is substantially maintainedafter about 100 standard laundry washings. Furthermore, when thepolymerically coated aluminum metal element is adhered to a hybridarticle, the polymerically coated aluminum metal element remains adheredto decorative article 100 after about more than 100 standard laundrywashings.

Typically, the sublimation dye print quality of the polymerically coatedaluminum element is substantially superior to the sublimation dye printquality on textiles, flock, or free standing polymeric films.Sublimination dye printed images on the polymerically coated aluminummetal element are one or more of substantially sharper, clearer, andcleaner with more true and vibrant color then sublimination dyed printedimages on textiles. Moreover, the sublimation dye printed polymericallycoated aluminum metal element is substantially more durable thansublimation dye printed textiles and flock. That is, the sublimation dyeprinted image contained in polymerically coated aluminum metal elementis substantially maintained after about 100 standard laundry washings.Furthermore, when the polymerically coated aluminum metal element isadhered to a hybrid article, the polymerically coated aluminum metalelement remains adhered to decorative article 100 after about more than100 standard laundry washings.

The insert 108 can comprise a polymeric material containing a hologram.The hologram-containing insert 108 can provide a level of authenticationof the decorative article 100. While not wanting to be limited byexample, a decorative article 100 in the form of a security badge havinga hologram-containing insert 108 can be easily authenticated anddifficult to reproduce.

The insert 108 can be a sublimation printable sheet material. Thesublimation printable sheet material can be a polymeric sheet materialcapable of accepting sublimation dyes. The sublimation printable sheetmaterial can be one of a rigid or semi-rigid polymeric material. Morespecifically, the sublimation printable sheet material can be one of arigid or semi-rigid, white polymeric material.

In some configurations, the sublimation printable sheet materialcomprises a first polymer and a second polymer. While not wanting to belimited by example, the sublimation printable sheet material cancomprise a polyester, polyester copolymer, polyester polymer alloy,polyester polymer blend or a combination thereof. That is, in accordancewith some configurations, one or both of the first and second polymerscomprise polyester.

The first and second polymers, respectively, have first and secondsoftening temperatures and first and second melt temperatures. Thesecond softening temperature is greater than the first softeningtemperature and the second melt temperature is greater than the firstmelt temperature. Commonly, the second softening temperature is morethan 50 degrees Fahrenheit greater than the first softening temperature,more commonly more than 100 degrees Fahrenheit greater than the firstsoftening temperature, even more commonly more than 150 degreesFahrenheit greater than the first softening temperature, or yet evenmore commonly more than about 200 degrees Fahrenheit greater than thefirst softening temperature. Typically, the second softening temperatureis more than 50 degrees Fahrenheit greater than the first meltingtemperature, more typically more than 100 degrees Fahrenheit greaterthan the first melting temperature, even more typically more than 150degrees Fahrenheit greater than the first melting temperature, or yeteven more typically more than about 200 degrees Fahrenheit greater thanthe first melting temperature.

While not wanting to be limited by theory, at least one of first orsecond polymers generally has a melt or softening temperature of morethan about 350 degrees Fahrenheit, more generally a melt or softeningtemperature of more than about 375 degrees Fahrenheit, even moregenerally a melt or softening temperature of more than about 400 degreesFahrenheit, yet even more generally a melt or softening temperature ofmore than about 425 degrees Fahrenheit, or still yet even more generallya melt or softening temperature of more than about 450 degreesFahrenheit. It is believed that having a sublimation printable sheetmaterial comprising a polymer having a softening temperature of morethan about 350 degrees Fahrenheit can substantially improve thesublimation printed image quality. For example, the sharper imagesand/or finer, sharper lines can be sublimated printed on sheet materialcomprising a polymer having a softening temperature more than about 350degrees Fahrenheit compared to a sheet material substantially lacking apolymer having a softening temperature of more than about 350 degreesFahrenheit.

The insert 108 can be according to some configurations a metalizedpolymeric material. The metalized polymeric material of insert 108commonly has one or both of a different metallic color and a texturizedsurface than one of the first 101 and second 102 layers.

The insert 108 can be according to some configurations a knitted orwoven textile. The woven and/or knitted material can contain asublimation printed image.

According to some configurations the insert 108 can include a polymericfill material. The polymeric fill material can comprise any polymericmaterial. Typically, the polymeric fill material is positioned in theone or more of the voids 105 in the form of a liquid and/or pastematerial. The polymeric fill material, after positioning the polymericfill material in the one or more voids, is solidified and/or cured.

While not wanting to be limited by theory, the polymeric fill materialcan be thermoplastic polymeric fill material. The thermoplasticpolymeric fill material can be positioned in the one or more voids 105while the thermoplastic polymeric fill material is substantially at orabove its melt temperature. The thermoplastic polymeric fill material,after being positioned in the one or more voids 105, can be cooled tosolidify the thermoplastic polymeric fill material within the one ormore voids 105.

The polymeric fill material can be a thermosetting-polymeric fillmaterial. The thermosetting-polymeric fill material can be positioned inthe one or more voids 105 while substantially in one of A- or B-stage.The thermosetting-polymeric fill material after being positioned in theone or more voids 105 can be one of cured or cooled to solidify thethermosetting-polymeric fill material within the one or more voids 105.For example, the thermosetting-polymeric material contained with the oneor more voids 105 can be solidified within the one or more voids 105 bysubstantially curing and/or C-staging the thermosetting polymeric fillmaterial.

The polymeric fill material can have a colored and/or metallic likeappearance. It can be appreciated that can one of partially orsubstantially completely fill the one or more voids 105.

The first 101 and second 102 layers can be positioned side-by-side orstacked one on top of the other as further described herein and/or inU.S. patent application Ser. No. 13/625,797, filed Sep. 24, 2012, whichis incorporated fully herein by this reference. A thermosetting orthermoplastic adhesive can adhesively join the first 101 and second 102layers. The adhesive can be in the form of an adhesive layer positionedbetween the first 101 and second 102 layers. The metalized film of oneor both of the first 101 and second 102 layers can have a texturizedsurface. The pattern and/or form of the texturized surface can vary overone or both of the first 101 and second 102 layers.

In another configuration, an intermediate layered structure, such as ametalized film and flock and/or a textile (in a stacked or side-by-sideconfiguration), is thermoformed in a, typically closed metal, die andoptionally one or more of the decorative elements are dimensionalized toprovide a highly attractive decorative article. In one application,flock is adhered, by one or both of a thermoplastic adhesive and an A-,B- or C-staged thermosetting adhesive to a surface of the metalizedfilm, which assembly is placed in a metal die and thermoformed. Not onlyis the flock more tightly adhered to the metalized film by the processbut also the assembly can be formed into a nonplanar, three-dimensionalarticle through thermoforming. An added benefit is that the flock and/ormetalized film is/are precisely cut by the die during thermoforming. Theflock can also be dimensionalized by and during thermoforming.

FIG. 10 depicts a decorative article 100 according to an aspect of thepresent disclosure. The hybrid article comprises a metalized material1310 and dyed layer film 1320. The metalized material 1310 has atexturized surface 1315 containing one or more voids 105. Positioned inthe one or more voids 105 is an insert exposed surface 104 of thecolor-enhancing layer 168. It can be appreciated that has a plurality oftexturized surfaces having differing attractive patterns 1315 a, 1315 b,etc. The decorative article 100 further includes a wall 107 containingan insert 108.

An example of a decorative article 100 is a pin-backed badge. Thedecorative article 100 can be used as patch to be sewn on to substrate.Moreover, the decorative article 100 can be backed with a pressuresensitive adhesive for use as a stick-on patch or backed with a heatsealed adhesive film for heat application to a desired substrate.

In some configurations, taking the shape of the substrate is desirable,but taking the shape of an underlying seam or contour is not. In suchconfigurations, the metalized film can include a thin spacer havingsubstantially sufficient flexibility to conform to the general shape ofthe substrate but substantially sufficient rigidity to not substantiallyconform to substrate irregularities, such as seams, channels and/orgrooves. Non-limiting examples of such a thin spacer are thin mylarfilms and silicon foam pads. In some configurations, the thin spacer hasa sufficiently high softening temperature so as to substantially conformto substrate irregularities during lamination. While not wanting to bebound by theory, it is believed that the high softening temperature ofthe thin spacer prevents the thin spacer from softening duringlamination and conforming to the substrate irregularities when one orboth of heat and pressure are applied during lamination. Similarly,lesser amounts of heat and/or pressure can be applied to the spacerand/or metalized film positioned about the substrate irregularities todecrease and/or eliminate the confirming of the metalized film tosubstrate irregularities.

The thin spacer many be applied to some or all of the metalized film. Insome configurations, the tin spacer may be applied to a portion ofmetalized film in contact with the substrate irregularities.Furthermore, in some configurations, the thin spacer is positionedbetween the metalized film and the substrate. A first spacer surface ofthe thin spacer is adhesively bond to the metalized film by a firstspacer adhesive. The thin spacer has a second spacer surface in anopposing relationship to the first spacer surface. The second spacersurface may or may not have a second space adhesive positioned on it. Insome configurations, the second surface of the thin spacer (that is, thethin spacer surface positioned nearest the substrate) is substantiallyfree of adhesive about the portion of the thin spacer positioned abovethe substrate irregularities. However, the second surface of thin spacernot positioned about the substrate irregularities may include a secondspacer adhesive. The thin spacer and metalized film are adhered to thesubstrate by the second spacer adhesive. It can be appreciated, that thethin spacer and metalized film are not adhered to the substrateirregularity. As such, the thin spacer and metalized film do notsubstantially conform with the surface irregularity. Furthermore, it isbelieved that the thin spacer and metalized film can move substantiallyfreely about the substrate irregularity.

A number of variations and modifications of the disclosure can be used.It would be possible to provide for some features of the disclosurewithout providing others.

The present disclosure, in various aspects, embodiments, andconfigurations, includes components, methods, processes, systems and/orapparatus substantially as depicted and described herein, includingvarious aspects, embodiments, configurations, subcombinations, andsubsets thereof. Those of skill in the art will understand how to makeand use the various aspects, aspects, embodiments, and configurations,after understanding the present disclosure. The present disclosure, invarious aspects, embodiments, and configurations, includes providingdevices and processes in the absence of items not depicted and/ordescribed herein or in various aspects, embodiments, and configurationshereof, including in the absence of such items as may have been used inprevious devices or processes, e.g., for improving performance,achieving ease and\or reducing cost of implementation.

The foregoing discussion of the disclosure has been presented forpurposes of illustration and description. The foregoing is not intendedto limit the disclosure to the form or forms disclosed herein. In theforegoing Detailed Description for example, various features of thedisclosure are grouped together in one or more, aspects, embodiments,and configurations for the purpose of streamlining the disclosure. Thefeatures of the aspects, embodiments, and configurations of thedisclosure may be combined in alternate aspects, embodiments, andconfigurations other than those discussed above. This method ofdisclosure is not to be interpreted as reflecting an intention that theclaimed disclosure requires more features than are expressly recited ineach claim. Rather, as the following claims reflect, inventive aspectslie in less than all features of a single foregoing disclosed aspects,embodiments, and configurations. Thus, the following claims are herebyincorporated into this Detailed Description, with each claim standing onits own as a separate preferred embodiment of the disclosure.

Moreover, though the description of the disclosure has includeddescription of one or more aspects, embodiments, or configurations andcertain variations and modifications, other variations, combinations,and modifications are within the scope of the disclosure, e.g., as maybe within the skill and knowledge of those in the art, afterunderstanding the present disclosure. It is intended to obtain rightswhich include alternative aspects, embodiments, and configurations tothe extent permitted, including alternate, interchangeable and/orequivalent structures, functions, ranges or steps to those claimed,whether or not such alternate, interchangeable and/or equivalentstructures, functions, ranges or steps are disclosed herein, and withoutintending to publicly dedicate any patentable subject matter.

What is claimed is:
 1. A decorative article, comprising: an adhesivelayer; and a metalized flexible polymeric layer, wherein the adhesivelayer comprises polyurethane, wherein the adhesive comprises a color,wherein the adhesive layer is adhered to the metalized flexiblepolymeric layer, wherein the metalized flexible polymeric layer has oneor more voids, wherein the metalized flexible polymeric layer ispositioned on a decorative surface to be visible to a viewer; and aapportion of the adhesive layer is visible, within the one or morevoids, to the viewer.
 2. The decorative article of claim 1, furthercomprising: an item of apparel, wherein the metalized flexible polymericlayer is adhered to the item of apparel by the adhesive layer.
 3. Thedecorative article of claim 1, wherein the metalized flexible polymericlayer has one or more of the following properties: i) a density of nomore than about 1.5 g/cm³; ii) a tensile strength of no more than about10⁷ Pascals; and iii) a modulus of elasticity or flex strength of nomore than about 10⁹ Pascals.
 4. The decorative article of claim 1,wherein the metalized flexible polymeric layer comprises a metalizedfilm having a metallic appearance.
 5. The decorative article of claim 1,wherein the metalized flexible polymer layer comprises polyurethane. 6.The decorative article of claim 1, the one or more voids havesubstantially smooth and level void walls.
 7. The decorative article ofclaim 1, wherein the metalized flexible polymeric layer comprises a highfrequency molded polymeric material.
 8. The decorative article of claim1, wherein the adhesive layer is not visible through the metalizedflexible polymeric layer.
 9. The decorative article of claim 1, furthercomprising: an optically transmissive layer positioned between themetalized flexible polymeric layer and the adhesive layer.
 10. Thedecorative article of claim 9, wherein the optically transmissive layercomprises a thermoplastic resin film.
 11. The decorative article ofclaim 9, further comprising: a color-enhancing layer positioned betweenthe optically transmissive layer and the adhesive layer, wherein thecolor-enhancing layer comprises a translucent color-containing inklayer.
 12. The decorative article of claim 1, further comprising: anitem of apparel, wherein the metalized flexible polymeric layer isadhered to the item of apparel by the adhesive layer.
 13. A decorativearticle, comprising: a flexible polymeric layer comprising polyurethaneand having a metallic appearance; an adhesive layer adhered to theflexible polymeric layer, wherein the flexible polymeric layer has oneor more voids; and an insert position in one or more voids.
 14. Thedecorative article of claim 13, further comprising: wherein the insertis positioned in some but not all of the one or more voids and whereinthe adhesive layer is visible in the other of one or more voids nothaving the insert positioned therein.
 15. A method, comprising:providing a decorative article intermediate comprising a flexiblepolyurethane layer having a metallic appearance; registering theflexible polyurethane layer with a laser etching system; and etching theflexible polyurethane layer by contacting the flexible polyurethanelayer with a laser beam generated by the laser system, wherein thecontacting of the laser beam with the flexible polyurethane layer formsone or more voids in the flexible polyurethane layer, wherein in one ofi) and (Iii) is true: (i) wherein the decorative article intermediatecomprises an adhesive layer adhered to the flexible polymericpolyurethane layer and wherein the adhesive layer is visible within theone or more voids; or (ii) further comprising: contacting the flexiblepolymeric polyurethane layer having one or more voids with an adhesivelayer, wherein the adhesive layer is visible within the one or morevoids.
 16. The method of claim 15, wherein the registering comprises oneof a mechanical registration, optical registration, electro-mechanicalregistration, computerized registration, or combination thereof.
 17. Themethod of claim 15, wherein the contacting of a laser beam the flexiblepolyurethane layer removes at least some of the flexible polyurethanelayer.
 18. The method of claim 17, wherein the contacting of the laserbean with the flexible polyurethane layer comprises a sequentialcontacting of the laser beam with the flexible polyurethane layer. 19.The method of claim 18, wherein each sequential contacting of the laserbeam with the flexible polyurethane layer removes at least some of theflexible polyurethane layer contained in the one or more voids.
 20. Themethod of claim 19, wherein (i) is true and wherein the laser etchingcomprises sufficient laser beam energy and sufficient sequential passesof the laser beam to remove at least most, if not all, of the flexiblepolyurethane layer contained in the one or more voids but little, ifany, of the adhesive layer material.
 21. A decorative article,comprising: an adhesive layer; and a flexible metalized polyurethanelayer, wherein the adhesive layer is adhered to the flexible metalizedpolyurethane layer having one or more voids, wherein the flexiblemetalized polyurethane layer is positioned on a decorative surface to bevisible to a viewer, and wherein a portion of the adhesive within theone or more voids is visible to a viewer.
 22. The decorative article ofclaim 21, the one or more voids have substantially smooth and level voidwalls.
 23. The decorative article of claim 21, wherein the adhesivelayer is not visible through the flexible metalized polyurethane layer.24. The decorative article of claim 21, further comprising: an opticallytransmissive layer positioned between the flexible metalizedpolyurethane layer and the adhesive layer, wherein the adhesive layer isadhere to the flexible metalized polyurethane layer, wherein theflexible metalized polyurethane layer has one or more voids, wherein theflexible metalized polyurethane is positioned on a decorative surface tovisible to a viewer, and wherein a portion of the adhesive layer withinthe one or more voids is visible to the viewer.
 25. The decorativearticle of claim 25, wherein the optically transmissive layer comprisesa thermoplastic resin film.
 26. The decorative article of claim 25,further comprising: a color-enhancing layer positioned between theoptically transmissive layer and the adhesive layer, and wherein thecolor-enhancing layer comprises a translucent color-containing layer.